Portable low profile drive-over truck dump conveyor system

ABSTRACT

A portable truck dump comprises a conveyor system mounted on an elongate frame to transport material from a first end of the frame to a second, opposite end of the frame. A grate is positioned over the conveyor system and is supported by first and second sides of the frame. A ramp extends generally perpendicular to the frame on each side of the frame next to the grate to provide a drive-over access for a material transport vehicle to deposit its load over the grate and onto the conveyor system. A first end of each ramp immediately adjacent to the frame is pivotally connected to the frame to allow the frame to be articulated towards the grate. A second end of each ramp spaced from the frame is supported above but in close proximity to the ground. A support frame is associated with each ramp for supporting the second end of each ramp. A drive-on ramp contacts an end portion of the support frame.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This is a continuation of U.S. patent application Ser. No. 12/589,573,filed Oct. 26, 2009, which is a continuation of U.S. patent applicationSer. No. 12/220,754, filed Jul. 28, 2008, now U.S. Pat. No. 7,607,529,which is a continuation of U.S. patent application Ser. No. 11/322,133,filed Dec. 29, 2005, now U.S. Pat. No. 7,424,943, which claimed priorityto provisional patent application Ser. No. 60/728,614, filed Oct. 20,2005.

BACKGROUND OF THE INVENTION

The present invention relates to material transport vehicle unloadingsystems, and more particularly, to a portable drive-over truck dumpconveyor system with a low profile drive-over ramp.

Material transport vehicle unloading conveyor systems are commonly usedwhenever there is a need to transport and store materials at a varietyof locations. For example, the agricultural and aggregate industries useunloading conveyor systems to transport and stockpile various materials.Conventional unloading conveyor systems include a material deposithopper that feeds a conveyor system to transport the deposited materialto a final destination for stockpiling. The deposit hopper of suchunloading systems typically has a height of six feet or more above theground. Access to the hopper for material transport vehicles is providedby building large earthen ramps on either side of the hopper. The set uptime for such unloading conveyor systems requires a large volume ofearthen material (e.g., 1,000 cubic yards or more) and time (e.g., tenhours or more) to construct the earthen ramps. As such, conventionalunloading conveyor systems are not suited to circumstances requiringperiodic relocation of the unloading conveyor, such as road constructionprojects. There is a need for a material transport vehicle unloadingsystem that is portable, quick and easy to set up, and able to berelocated at minimal cost.

BRIEF SUMMARY OF THE INVENTION

A portable material transport vehicle dump system comprises alongitudinally extending frame that carries a material conveying systemgenerally from a first end of the frame to a second end of the frame.The first end of the frame is in close proximity to a ground surface. Agrate is supported by the frame near the first end of the frame so as tobe positioned over a portion of the conveying system. A pair of rampsare connected to the frame on opposite sides of and aligned with thegrate. Each ramp of the pair of ramps has a first portion that isengageable with the ground surface and a second portion that issupportable above the ground surface. The second portions define, incombination with the grate, a drive over surface for a materialtransport vehicle when second portions are in a first lowered position.The first portion of each ramp comprises a U-shaped frame having a pairof side frame members and an end frame member connected between the pairof side frame members at an end of each side frame member that is spacedfrom the longitudinally extending frame. The end frame member defines aheight above the ground surface. An end portion of the drive oversurface of the second portion of each ramp is positioned adjacent to theend frame member of the U-shaped frame when the second portion of eachramp is in the first lowered position. The second portion of each rampis pivotable away from the first portion while the first portion remainsin contact with the ground surface.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of one embodiment of a portable drive-overtruck dump conveyor system of the present invention.

FIG. 2 is a side view of the conveyor system of FIG. 1.

FIG. 3 is a diagrammatic side view of one ramp section of the conveyorsystem of the present invention.

FIG. 4 is a perspective view of the conveyor system of FIG. 1 with thedrive-over ramp system in the down position.

FIG. 5 is a perspective view of the conveyor system of FIG. 1 with thedrive-over ramps pivoted toward the material receiving area of theconveyor system.

FIG. 6A is side view of a belly dump material transport vehiclepositioned with the belly dump opening over the material receiving areaof the conveyor system of the present invention.

FIG. 6B is side view of a rear dump material transport vehiclepositioned with the dump opening over the material receiving area of theconveyor system of the present invention.

FIGS. 7 and 8 are an end views of the drive-over ramp system of thepresent invention with the front side walls removed to better illustratethe ramp cleaning operation of the drive-over ramp system of the presentinvention.

FIG. 9 is a perspective view of a second embodiment of the ramp systemof the present invention.

DETAILED DESCRIPTION

FIG. 1 is a perspective view of one embodiment of a low profile,portable drive-over truck dump conveyor system 10 of the presentinvention. Conveyor system 10 is generally comprised of a longitudinallyextending frame 12 configured at first end 14 for connection to a towingvehicle and configured at second end 16 with a wheeled axle system 18,which allows conveyor system 10 to be easily transported on a roadway toa desired work site. Wheeled axle system 18 can also be replaced byskids to permit off-road portability of conveyor system 10. Carried byframe 12 adjacent to first end 14 is a drive-over ramp system 20, whichas depicted in FIG. 1 is in a raised, stored position for transport ofconveyor system 10. Also carried by frame 12 is a conventional endlessconveyor belt assembly 22, which generally extends from first end 14(beneath ramp system 20) to second end 16 and is supported on aplurality of idler rollers 24 mounted to frame 12. Conveyor beltassembly 22 transports material deposited relative to ramp system 20 toa hopper 25 for delivery to subsequent conveyor systems or materialtransport vehicles (not shown).

The drive-over ramp system 20 is uniquely configured to define alow-profile material deposit access for belly dump and rear dumpmaterial transport vehicles. Ramp system 20 generally includes a firstramp section 26 mounted on a first side 27 of frame 12, and a secondramp section 28 mounted on second side 29 of frame 12. Located betweenfirst and second ramp sections 26, 28 is a third ramp section 30. Rampsection 30 comprises a grate supported by frame 12, which allowsmaterial deposited on ramp system 20 to access the endless conveyor beltassembly 22.

Each ramp section 26, 28 includes a ramp support frame 32 and a ramp 34,which in the embodiment shown are pinned together in a raised and storedposition for transport or storage of conveyor system 10. Each rampsection 26, 28 of ramp system 20 may be stabilized in this raised andstored position by connecting the respective ramp section to frame 12,such as with bracing bar 36. In one embodiment bracing bar 36 isconnected to each ramp section 26, 28 by providing a flange 39 on, forexample, ramp support frame 32.

In one embodiment, each ramp support frame 32 comprises a perimeter ofmetal frame members that include a pair of side frame members 38 and apair of end frame members 40A and 40B. End frame member 40B has aheight, as measured between lower frame edge 42 and upper frame edge 44,which is greater than the height of end frame member 40A. In oneembodiment, end frame member 40B has a height of less than about twentyfive inches. In a particular embodiment, end frame member 40B has aheight of about twenty two inches. End frame members 40A, 40B areconnected to side frame members 38 by welding. A metal gusset 46 isfurther welded to each side frame member 38 and a respective end portionof end frame member 40B. End frame members 40A and 40B may be stabilizedsuch as by a metal brace 48 connected between frame members 40A, 40B. Inthe embodiment shown, each ramp support frame 32 is connected to frame12 by a hinge plate 50 that is welded to each side frame member 38adjacent to end frame member 40A. Hinge plates 50 are pivotallyconnected to frame 12. The pivotal connection of ramp support frame 32provides a convenient way for storing and deploying ramp support frame32 of each ramp section 26, 28. When conveyor system 10 is set up forunloading material transport vehicles, ramp support frame 32 rests onthe ground. Ramp support frame 32 provides two independent functions.First, ramp support frame 32 serves as a low profile support structurefor building an earthen ramp to access the ramp system 20. Second, rampsupport frame can additionally serve as a stable base to support ramp 34at a level of end frame member 40B. The present invention contemplatesutilizing the first function of ramp support frame 32 alone, or acombination of the first and second function of ramp support frame 32.

FIG. 2 is a side view of the conveyor system 10 with the ramp supportframe 32 removed. As shown in FIGS. 1 and 2, each ramp 34 of ramp system20 comprises a generally rectangular metal frame 51 which includesplurality of cross-support members 52 connected between opposing endframe members 54A, 54B. Cross-support members 52 are spaced apartrelative to the side frame members 55 and to one another to providesupport for a metal decking 56. Metal decking 56 is secured to a firstsurface of the ramp frame 51 and cross-support members 52 by welding.Connected to a second, opposite surface of cross-support members 52 andside frame members 55 is a metal beam 58. Beam 58 has a length greaterthan a width of ramp 34 and extends generally transverse tocross-support members 52. Opposing ends of beam 58 are connected to oneend of a hydraulic cylinder 60, which has its opposite end connected toa flange 62 mounted on frame 12 (FIG. 1). Hydraulic cylinders 60 areconnected to a conventional hydraulic system 64 comprising a pump andfluid reservoir carried by frame 12. Hydraulic cylinders 60 are dualactuated hydraulic cylinders which allow ramp system 20 to be raised andlowered relative to the ground in a manner to be described more fullyherein.

As shown in FIG. 2, frame 12 of conveyor system 10 is comprised of afirst frame section 100, which carries the wheeled axle system 18 andthe drive-over ramp system 20, and a second frame section 102, whichcarries a portion of the conveyor belt assembly 22. First frame section100 has a first linear portion 104, which is configured to rest flat onthe ground 105, and a second linear portion 106, which extends at anangle relative to the first linear portion 104. The first frame section100 has an exemplary length of about forty three feet. The height of thefirst linear portion 104 by ramp system 20 is less than about twentyfive inches.

The second frame section 102 has a first linear portion shown generallyat 108 which is complimentary to first linear portion 104 of the firstframe section 102. First linear portion 108 is sized to fit betweenopposite sides of first frame section 102 and is pivotally connected tothe first frame section 102. Second frame section 102 also includes asecond linear portion 110 which extends at an angle relative to thefirst linear portion 108. To assist the conveyor belt of conveyor beltassembly 22 to angularly transition from the second conveyor section 102to the first frame section 100, a pair of wheels 103 are rotationallymounted relative to first frame section 100 adjacent to the ramp system20. Wheels 103 engage the upper surface of the conveyor belt 109 toredirect the conveyor belt 109 for travel beneath the third ramp section30.

The second linear portion 110 rests on a pedestal 112 carried by firstframe section 100 when the second frame section 102 is in a firstposition. In the exemplary embodiment, the height H1 of second end 16relative to the ground 105 when the second frame section 102 is in thefirst position is about twelve feet, three inches. The second framesection 102 may be elevated above the pedestal 112 by a pair ofhydraulic cylinders 114 mounted between opposite sides of the secondlinear portion 110 and the second linear portion 106 of the first framesection 100. Adjustable supports 116 are further provided between firstframe section 100 and second frame section 102 to assist in stabilizingthe second frame section 102 at the height selected. The overall lengthof first and second frame sections in the exemplary embodiment is aboutfifty two feet. In the exemplary embodiment, the height H2 of conveyorsystem 10, as defined by ramp system 20 in the up position, is aboutnine feet, four inches. Ramp system 20 has a width W of about ten feet,five inches.

FIG. 3 is a diagrammatic side view of one ramp section (e.g., rampsection 26) of ramp system 20. As shown in FIG. 3, ramp support frame 32is positioned with lower frame edge 42 in contact with the ground 105.As previously noted, end frame member 40B has a height greater than endframe member 40A, which in the exemplary embodiment shown isaccomplished by connecting two metal beams at their respective ends,such as by welding. Frame member 40B functions as a barrier to create anearthen ramp for material transport vehicles to access ramp system 20.In one preferred embodiment, frame member 40B has a relatively lowheight H3 above ground 105 such that less material is required to buildthe earthen ramp than truck dump systems currently known in the art.Also, as such, the preparation, set up time and cost of operatingconveyor system 10 is considerably less than existing truck dumpsystems. Known truck dump systems, for example, require an earthen ramphaving a height of six feet or greater, which requires over 1,000 cubicyards of material and approximately 8 to 10 hours to construct. In oneexample, frame member 40B has a height of about twenty two inches,although other dimensions of frame member 40B that yield a low profileearthen ramp are possible.

As further shown in FIG. 3, ramp support frame 32 may include a metalramp support beam 122 adjacent to frame member 40B for supporting endframe member 54B of ramp frame 51 when ramp 34 is in a first, loweredposition. Support beam 122 extends between side frame members 38 and issecured to the upper frame edge surface 44, such as by welding. Supportbeam 122 is dimensioned such that a lip 124 of deck 56 lies on thetop-most edge surface of end frame member 40B when ramp 34 is resting onbeam 122.

Each side frame member 38 of ramp support frame 32 further includes ametal flange 39, as previously discussed, and metal flange 126. Flanges39 are secured to side frame members 38 such as by welding. Flanges 126are also secured to side frame members 38 such as be welding and areprovided with a through hole for linking ramp support frame 32 tocorresponding flanges 128 associated with beam 58 on opposite sides ofbeam 58, such as with a metal pin. When flanges 126 and 128 are pinnedtogether, ramp support frame 32 can be raised to the raised and storedposition (shown in FIG. 1) along with ramp 34. When conveyor system 10is configured for unloading a material transport vehicle, each rampsection 26, 28 is moved to a second, lowered position with the rampsupport frame 32 resting on the ground 105. The metal pins connectingflanges 126 and 128 are then removed, thereby allowing ramp 34 to beraised and lowered independent of the ramp support frame 32.

In the embodiment shown, ramp support frame 32 and ramp 34 areconfigured to pivot about a common pivotal connection. Each side framemember 55 of ramp frame 51 includes a hinge plate 128 secured to an endportion of the respective side frame member 55, such as by welding. Rampframe 51 has a width slightly less than a width of ramp support frame 32such that hinge plates 50 overlap an outer surface 130 of hinge plates128. The configuration and placement of hinge plates 128 is selected tolocate the pivot point P of hinge plate 128 in close proximity to theinward edge E of the metal decking 56 of ramp 34. Pivot point P islocated on frame 12 to maintain edge E of metal decking in closeproximity to the edge of third ramp section 30 when ramp 34 is in eitherthe raised or lowered position (see e.g., FIG. 1)

Associated with each side frame member 55 of ramp sections 26, 28 is aside wall 132, which extends generally from end frame member 54B to edgeE of metal decking 56. Side Wall 132 is secured to side frame members 55by a plurality of spaced metal braces 134 that are welded to the outersurface 136 of each side frame member 55 and the outer surface 138 ofside wall 132. A lower edge 140 of side wall 132 fits close against sideframe member 55. The upper edge 142 of side wall is sloped to define thegreatest wall height at or near the pivot point P, which corresponds tothe area where material is deposited, with the lowest wall heightlocated near the end frame member 54B. Side walls 132 function to retainexcess material on the decking 56 of ramp 34 as it is being deposited bya material transport vehicle.

FIG. 4 is a perspective view of conveyor system 10 with ramp sections26, 28 is the second, lowered position. With the ramp support frames 32of each ramp section resting on the ground, earthen ramps 150 are madeto slope away from the end frame member 40B of each ramp support frameto allow material transport vehicles to access the drive-over rampsystem 20. As further shown in FIG. 4, frame 12 is provided with a pairof side walls 152 adjacent to the third ramp section 30 to retain excessmaterial on ramp system 20 as it is being desposited by the materialtransport vehicle. Side walls 152 are connected to respective portionsof frame 12 by a plurality of metal braces 154 in the manner describedrelative to side walls 132. Side walls 152 are located to allow the sidewalls 132 of ramp sections 26, 28 to move between the facing surfaces156 of side walls 152. As shown in FIG. 5, when ramps 34 are actuatedaway from the second, lowered position toward the first, raisedposition, the earthen ramps 150 are not disturbed and remain in contactwith the end frame members 40B. Ramp support frames 32 ensure that ramps34 are consistently supported relative to the ground after the rampshave been moved between the first and second positions.

As further shown in FIG. 5, a flap 157 may be connected to decking 56along edge E to cover a gap between ramp 34 and the grate of rampsection 30 as ramp 34 is actuated toward the raised position. Flap 157has a width sufficient to overlap an end portion of the grate andthereby prevent material deposited onto ramp system 20 from accumulatingbeneath ramp 34. Flap 157 may be a strip of conveyor belt material orany suitable durable and flexible material. Flap 157 may be connected todecking 56 by bolts to permit periodic replacement of the flap as wearoccurs.

FIGS. 6A and 6B are end diagrammatic views of the ramp system 20 withside walls 132 and 152 removed demonstrating material being deposited bydifferent types of material transport vehicles. The deposited materialis shown in a static position, although it is to be appreciated that thematerial deposited is being rapidly carried away from the third rampsection 30 by the conveyor belt system 20. As shown in FIG. 6A, rampsystem 20 is accessible by a belly-dump style material transporttruck/trailer system 160. The belly-dump gates 162 of system 160 arepositioned over the ramp system 20 with the gates 162 substantiallycentered on the third ramp section 30. As shown in FIG. 6A, once thegates 162 are opened, material falls onto the ramp system. Thebelly-dump gates have a length slightly greater than the width of thirdramp section 30. As such, a small portion 164 of material is depositedon the ramp 34 of each ramp section 26, 28. When the portion 164 ofmaterial is at a level of the gates 162, the remaining material fallingfrom gates 162 is deposited on the third ramp section 30. The materialpasses through the grates of section 30 and onto conveyor belt 109 ofthe moving conveyor belt system 22. Similarly, as shown in FIG. 6B, rampsystem 20 is accessible by a rear-dump style material transport vehicle166. Vehicle 166 is backed onto one ramp 34 until the rear dump gate 168is adjacent to the third ramp section 30 and the material is thendeposited onto the ramp system 20. A substantial portion of the materialis directed through the grates of the third ramp section and onto themoving conveyor belt system 20, with some overflow falling on each rampof ramp sections 26, 28.

FIGS. 7 and 8 are enlarged end views of ramp system 20 at the conclusionof an unloading operation of a material transport vehicle. As shown inFIG. 7, after the contents of the material transport vehicle have beendeposited through the grate of the third ramp section 30, the smallportion 164 of material remains on the ramp 34 of each ramp section 26,28. As shown in FIG. 8, to clear the material off of ramps 34, each rampsection 26, 28 is pivoted away from the ramp support frame 32 until thematerial is fed into the grate of the third ramp section 30. Rampsections 26, 28 are then lowered onto the ramp support frames 32 toallow another material transport vehicle to dump its material load.

FIG. 9 is a perspective view of a second embodiment of ramp system 20,which employs a pair of ramp support frames 180. Each ramp support frame180 is generally comprised of side frame members 182, 184 and an endframe member 186. Side frame members 182, 184 extend generally normal toframe 12 of conveyor system 10 adjacent to drive-over ramp system 20 andmay have free ends 188 connected to frame 12. Alternatively free ends188 are maintained relative to frame 12 by virtue of the earthen ramp(not shown) that abuts end frame member 186. As shown in FIG. 9, in oneembodiment frame 12 is provided with a pair of spaced flanges 190, eachflange 190 have a through hole. The free end 188 of side frame members182, 184 may be provided with a corresponding flange that is receivedbetween flanges 190 and connected with a metal pin. The construction andconnection of end frame member 186 to side frame members 182, 184 issubstantially identical to ramp support frame 32. Further, in oneembodiment, a ramp support beam such as ramp support beam 122 of rampsupport frame 32 is located adjacent to end frame member 186 to supportthe end frame member 54B of ramp frame 51. Alternatively, ramps 34 maybe supported by placing a support base on the ground between side framemembers 182, 184. A suitable support base may comprise a concrete blockor metal beam. Additionally, ramp 34 may be supported relative to theground by connecting one or more legs 200 to the underside of ramp 34along and/or adjacent to end frame member 54B. Legs 200 may be heightadjustable and removable from the underside of ramp 34.

When it is desired to transport conveyor system 10 to a new location,ramp support frame 180 can be stored relative to each ramp section 26,28. As shown in FIG. 9, each side frame member 55 of ramp frame 51 isprovided with a first and second pair of flanges 192 which align withcomplimentary flanges 194 mounted on side frame members 182, 184 of rampsupport frame 180. Flanges 192 and 194 are provided with complimentarythrough holes. To secure ramp support frames 180 to ramp sections 26,28, each ramp 34 is lowered until flanges 194 register between flanges192 with the respective holes in alignment. Metal pins are then insertedin the holes of flanges 192 and 194. If the free ends 188 of side framemembers are connected to frame 12, the free ends are disconnected. Rampsections 26, 28 can then be raised to the first, stored position alongwith the ramp support frames 180. Ramp support frames 180 provideanother convenient way of deploying and storing a ramp support frame foruse with the ramp system of the present invention.

Although the present invention has been described with reference topreferred embodiments, workers skilled in the art will recognize thatchanges may be made in form and detail without departing from the spiritand scope of the invention.

1. A portable conveyor system for unloading material transport vehiclescomprising: a frame having a first end, a second end, a first side and asecond side, the frame configured for connection to a towing vehicle,the frame carrying a belt conveyor system generally from the first endto the second end, a portion of the frame adjacent to the first endconfigured to rest on a ground surface; a grate supported by the framenear the first end of the frame, the grate being positioned over aportion of the belt conveyor system; a first drive-over ramp pivotallyconnected to the first side of the frame adjacent to the grate; a seconddrive-over ramp pivotally connected to the second side of the frameadjacent to the grate; the first drive-over ramp, second drive-over rampand grate capable of supporting a material transport vehicle fordepositing material through the grate when the first and seconddrive-over ramps are in a first position, the first and seconddrive-over ramps capable of catching excess material deposited by thematerial transport vehicle, the first and second drive-over rampspivotable to a second position to clear the excess material off of theramps into the grate.